US20100162843A1 - Rack and manufacturing method thereof - Google Patents

Rack and manufacturing method thereof Download PDF

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Publication number
US20100162843A1
US20100162843A1 US12/447,785 US44778507A US2010162843A1 US 20100162843 A1 US20100162843 A1 US 20100162843A1 US 44778507 A US44778507 A US 44778507A US 2010162843 A1 US2010162843 A1 US 2010162843A1
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US
United States
Prior art keywords
rack
teeth
rack teeth
axial direction
plastic working
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US12/447,785
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English (en)
Inventor
Kazuto Kobayashi
Yuki Mizushima
Kotaro Hirota
Akira Tsubouchi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
NSK Ltd
Original Assignee
NSK Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP2007132561A external-priority patent/JP5352965B2/ja
Priority claimed from JP2007166047A external-priority patent/JP2009000734A/ja
Application filed by NSK Ltd filed Critical NSK Ltd
Assigned to NSK, LTD. reassignment NSK, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HIROTA, KOTARO, KOBAYASHI, KAZUTO, MIZUSHIMA, YUKI, TSUBOUCHI, AKIRA
Publication of US20100162843A1 publication Critical patent/US20100162843A1/en
Abandoned legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H55/00—Elements with teeth or friction surfaces for conveying motion; Worms, pulleys or sheaves for gearing mechanisms
    • F16H55/02—Toothed members; Worms
    • F16H55/26—Racks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/12—Forming profiles on internal or external surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/76—Making machine elements elements not mentioned in one of the preceding groups
    • B21K1/767—Toothed racks
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y10T29/49467—Gear shaping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y10T29/49467—Gear shaping
    • Y10T29/49472—Punching or stamping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49462—Gear making
    • Y10T29/49467—Gear shaping
    • Y10T29/49474—Die-press shaping
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T74/00—Machine element or mechanism
    • Y10T74/19—Gearing
    • Y10T74/19642—Directly cooperating gears
    • Y10T74/1967—Rack and pinion

Definitions

  • the present invention relates to the improvement of a manufacturing method for a rack that is installed in a rack and pinion steering apparatus as a steering apparatus for applying a steering angle to the steering wheels of an automobile, for example.
  • a rack and pinion steering apparatus which uses a rack and pinion as a mechanism for converting rotational motion that is input from a steering wheel to linear motion for applying a steering angle, is widely used because it is made to be compact and lightweight, as well as has good rigidity and good feel of steering.
  • FIG. 40 shows an example of this kind of rack and pinion steering apparatus.
  • this steering apparatus the movement of a steering shaft 2 that is turned by the operation of a steering wheel 1 is transmitted to the input shaft 6 of a steering-gear unit 5 by way of a universal joint 3 and intermediate shaft 4 .
  • This steering-gear unit 5 comprises a pinion that is rotated and driven by the input shaft 6 , and a rack that meshes with the pinion.
  • the rack displaces in the axial direction, and pushes and pulls a pair of tie rods 7 that are connected to both ends of the rack, which applies the desired steering angle to the steering wheels.
  • patent documents 1 and 2 inventions related to the manufacturing method of a rack are disclosed in which a circular rod shaped material is tightly held between a pair of dies, and an uneven shape that is formed on one of these dies is transferred around part of the outer surface of the material, forming the teeth.
  • the excess material that is generated when forming the teeth material that is extruded from the portions that become the concave portions of the teeth) is forced out from between the dies from the side of the main portion of the rack in the shape of burrs, and then later removed.
  • the rack that is the object of the present invention comprises: a rod unit that is made of a metal material and has a circular cross section, and rack teeth that are formed by plastic working on one side surface in the radial direction of part of the rod unit in the axial direction of the rod unit.
  • the radius of curvature of the cross sectional shape of a portion that is separated in the circumferential direction from the portion where the rack teeth are formed is larger than the radius of curvature of the cross sectional shape of the outer surface of the remaining portion in the axial direction of the rod unit.
  • the rod unit can be made as a single member from the same kind of metal material over the entire length and from the outer surface to the center.
  • the rod unit could also comprise an outer layer member that is made into a tube shape from a first metal material, and an inner layer member that is made into a rod shape from a second metal material, and that is tightly fitted inside the outer layer member.
  • a first plastic working is performed on part in the axial direction of a circular rod shaped material that will become the rod unit, by compressing a portion in the circumferential direction of the part in the axial direction, and forming a partial cylindrical surface on the remaining portion in the circumferential direction of the part in the axial direction such that it has a radius of curvature that is larger than the radius of curvature of the outer surface of the material to obtain an intermediate material.
  • a second plastic working is performed to form rack teeth on the portion in the circumferential direction of the part in the axial direction of the intermediate material.
  • the first plastic working be an upsetting work.
  • the upsetting work by compressing the part in the axial direction of the material in the radial direction to make the portion of the outer surface of the part in the axial direction where the rack teeth will be formed into a flat surface portion, the remaining portion that is separated from this flat surface portion is formed into a partial cylindrical surface whose radius of curvature of the cross sectional shape is larger than the radius of curvature of the cross sectional shape of the outer surface of the material.
  • the second plastic working be a pressing work.
  • this pressing work the remaining portion that is separated from the flat surface portion of the part in the axial direction of the intermediate material is supported by a retaining hole of a die, and rack teeth are formed on the flat surface portion by pressing a teeth-formation punch, having an uneven shape corresponding to the teeth to be formed, against the flat surface portion.
  • the space between the inner surfaces of the retaining hole in the die be less than the outer diameter of the intermediate material in the width direction of the flat surface portion.
  • the teeth-formation punch presses this intermediate material into the retaining hole, and forms rack teeth on the flat surface while moving metal material of both ends in the width direction of this intermediate material to the flat surface portion.
  • the second plastic working be divided into a plurality of steps.
  • a teeth-formation punch having a shape that corresponds to the pressure angle that is less than the pressure angle of the rack teeth to be obtained, forms crude rack teeth.
  • a teeth-finishing punch having a shape that corresponds to the pressure angle of the rack teeth to be obtained, presses the crude rack teeth to form the crude rack teeth into the rack teeth.
  • plastic working be performed to increase the radius of curvature of the cross sectional shape of at least the edges from the base of the teeth to the tip of the teeth of both ends in the width direction of the crude rack teeth.
  • the teeth-finishing punch presses the crude rack teeth to form the crude rack teeth into the rack teeth.
  • the plastic working make the radius of curvature of the cross sectional shape of the edges from the base of the teeth to the tip of the teeth of both ends in the width direction of the crude rack teeth larger than the radius of curvature of the cross sectional shape of the edges from the base of the teeth to the tip of the teeth of both ends in the width direction of the completed rack teeth.
  • the crude rack teeth are formed, and a pair of flat flank surfaces is formed on both sides of the crude rack teeth.
  • plastic working is performed to increase the radius of curvature of the cross sectional shape of the base portion of the crude rack teeth.
  • the metal material that is moved by this plastic working is stopped by the flat flank surfaces, and the excess material is prevented from protruding outward in the radial direction further than a virtual cylindrical surface that extends from the partial cylindrical surface.
  • the second plastic working form the rack teeth, and form a pair of flat flank surfaces on both sides of the rack teeth. After that, sizing is performed to improve the precision of the rack teeth, where the metal material that is moved by this sizing is stopped by the flat flank surfaces, and the excess material is prevented from protruding outward in the radial direction further than a virtual cylindrical surface that extends from the partial cylindrical surface.
  • an ironing work in which the material is passed through an ironing die so as to reduce the outer diameter of the material except for part in the axial direction thereof is performed before the first plastic working.
  • the result is taken to be a preliminary intermediate material of which the outer diameter of the part in the axial direction of this material is larger than the outer diameter of the remaining portion in the axial direction, after which the first plastic working is performed on this preliminary intermediate material.
  • an ironing work in which the intermediate material is passed through an ironing die so as to reduce the outer diameter of this intermediate material except for part in the axial direction thereof is performed after performing the first plastic working and before performing the second plastic working.
  • the result is taken to be a second intermediate material of which the outer diameter of this part in the axial direction is larger than the outer diameter of the remaining portion in the axial direction, after which the second plastic working is performed on this second intermediate material.
  • an ironing work in which a circular rod shaped material that will become the rod unit is passed through an ironing die so as to reduce the outer diameter (or reduce to a desired cross sectional shape) of at least a portion in the axial direction of this material.
  • This ironing work is performed at least either: before performing a first plastic working in which a flat surface portion where the rack teeth will be formed (this not only includes a completely flat surface, but also includes a surface that could be considered in the same way as a flat surface, such as a curved surface having a large radius of curvature, or the like, or in other words, includes a surface that could be necessary in the previous stage when forming the rack teeth by the plastic working) on part in the axial direction of the material by compressing a portion in the circumferential direction of this part in the axial direction; or after performing this first plastic working and before performing a second plastic working of forming the rack teeth on the flat surface portion.
  • this ironing work can be performed as described below.
  • the ironing work can be performed before performing the first plastic working, to reduce the outer diameter (or reduce to a desired cross sectional shape) of the entire material in the axial direction.
  • the ironing work can be performed in at least the stage before performing the first plastic working, or after performing the first plastic working and before performing the second plastic working, to reduce the outer diameter (or reduce to a desired cross sectional shape) of a portion in the axial direction of the material nearer the base end side than a portion corresponding to where the rack teeth will be formed.
  • the ironing work can be performed before performing the first plastic working, to reduce the outer diameter of at least a portion corresponding to where the rack teeth will be formed of the part in the axial direction of the material (as necessary, this portion and a portion nearer the tip end side than this portion).
  • the ironing work can be performed before performing the first plastic working, to reduce the outer diameter (or reduce to a desired cross sectional shape) of a portion of the part in the axial direction of this material except for the portion nearer to the tip end side than the portion corresponding to where the rack teeth will be formed.
  • first ironing work it is possible to perform a first ironing work to reduce the outer diameter (or reduce to a desired cross sectional shape) of a portion nearer to the base end side than the portion corresponding to where the rack teeth will be formed of part in the axial direction of the material (and as necessary this portion and a portion nearer the tip end side than this portion), and then perform a second ironing work.
  • first and portion ironing works can be performed in reverse order.
  • securing the width dimension of the rack teeth is accomplished by making the width of a portion where the rack teeth will be formed of part in the axial direction of the rod unit greater than the outer diameter of the remaining portion in the axial direction of the rod unit. Also, securing the strength and rigidity can be accomplished by making this rod unit from a solid material. In other words, the width dimension of the portion where the rack teeth will be formed of part in the axial direction of the rod unit is expanded while pressing to compress the material, and the radius of curvature of the portion that is separated in the circumferential direction from the portion where the rack teeth will be formed is made to be greater than the radius of curvature of the outer surface of the material.
  • rack teeth having a width dimension that is large in comparison with the outer diameter of the material.
  • the portion where these rack teeth are formed differs from the rack teeth that are formed by pressing and expanding a hollow cylindrical tube shaped material as done in the conventional art disclosed in patent document 4 described above in that it is possible to secure sufficient thickness. It is possible to improve the strength and rigidity of the rack teeth portion by the amount that the width dimension is increased, and even further by the amount that the radius of curvature of the cross sectional shape of the portion that is separated in the circumferential direction from the portion where the rack teeth are formed is increased.
  • obtaining a lightweight rack without increasing more than necessary the outer diameter of the portion where the teeth are not formed is accomplished by making the outer diameter of the remaining portion in the axial direction of the rod unit small even though the width dimension of the rack teeth is secured.
  • the width dimension of the portion of part in the axial direction of the rod unit where the rack teeth are to be formed is made to be greater than the outer diameter of the remaining portion in the axial direction by compressing the portion of the cross sectional shape that originally had the same cross sectional area as the remaining portion in the axial direction, and making the portion where the rack teeth are to be formed flat.
  • the cross sectional area of part in the axial direction of the rod unit is nearly equal to the cross sectional area of the remaining portion in the axial direction. Therefore, the volume of the material that exists in the part in the axial direction of the rod unit where the rack teeth are to be formed is kept to a proper amount, and the excess material resulting from formation of the rack teeth does not protrude outward in the radial direction.
  • the movement of metal material that occurs during a second plastic working for forming the rack teeth is mainly movement from the bottom portion of the rack teeth to the tip portion of the teeth. Therefore, it is possible to keep the processing load for forming the rack teeth low, and it is possible to form the rack teeth by cold working, in which it is easier to secure precision when compared with hot or warm working.
  • the rod unit having an outer layer member and inner layer member By using layered construction for the rod unit having an outer layer member and inner layer member, it becomes possible to further secure the strength of the rack teeth and reduce the weight of the overall rack.
  • the outer layer member by making the outer layer member from a metal material for which it is easy to secure strength and resistance to wear such as a steel alloy like carbon steel or stainless steel, and by making the inner layer member from a lightweight metal material that can be plastically deformed such as an aluminum alloy, it is possible to maintain strength as well as obtain a lightweight rack.
  • the thickness of the outer layer member is made to be as small (thin) as possible and still be able to secure the strength and resistance to wear of the rack teeth and overall rack.
  • all of the process can be performed in a state in which the inside of the dies are not completely filled with the metal material.
  • all of the processes can be performed without so-called sealed formation, and the reaction force applied to the dies from the processed object in each process, and furthermore the stress that occurs in each of the dies due to that force is kept low, and thus it is possible to improve the durability of these dies, which also makes it possible to reduce costs.
  • the construction of the dies can be simple, so that formation is possible using general-purpose press equipment.
  • the stress occurring in the dies is kept low, so formation using cold forging is possible, and since change in the dimensions of the dies is suppressed, it is possible to improve the precision of the obtained rack more than when formed using hot or warm forging.
  • the process of forming the rack teeth using a pressing process in which the remaining portion in the circumferential direction of the part in the axial direction of the aforementioned intermediate material that is separated from the aforementioned flat surface is supported in a retaining hole, and a teeth-formation punch is pressed against the flat surface, further by moving the metal material from both end portions in the width direction of the intermediate material during pressing to the flat surface, or by performing this process in a plurality of steps, the rack can be made at sufficiently low cost and good precision.
  • the ironing work and/or diameter expansion process By performing an ironing work and/or diameter expansion process on the material or intermediate material before performing the plastic working for forming the rack teeth, it is possible to reduce the diameter of the portion that is separated in the axial direction from the portion where the rack teeth are formed, and reduce the overall weight of the rack, as well as it is possible to regulate the outer diameter (cross sectional shape) of the material that takes into consideration the volume of the metal material that is extruded by plastic working in relationship to the shape required for the completed rack. Differing from a cutting process such as swaging or turning which is required in the case of the conventional art disclosed in patent document 3 described above, the ironing work and diameter expansion process, which are a kind of plastic working, can segue into the other plastic working for forming the rack teeth or the like. Therefore, it is possible to suppress somewhat the rise in production cost of the rack that accompanies performing an ironing work or diameter expansion process.
  • FIG. 1 is a pictorial view of a rack of a first embodiment of the present invention.
  • FIG. 2 is a view as seen from direction A in FIG. 1 .
  • FIG. 3 is a view as seen from direction B in FIG. 1 .
  • FIG. 4 is an enlarged cross sectional view of the portion C-C in FIG. 3 .
  • FIG. 5 is a drawing of partial cross sectional views as shown from the same direction as FIG. 4 , and show the order of processing of the manufacturing method of the first embodiment.
  • FIG. 6 is a drawing of partial pictorial view showing the shape of the rack teeth before and after sizing.
  • FIG. 7 is a drawing that corresponds to the portion D-D shown in (D) of FIG. 5 , and shows the change in shape when the processing of the rack teeth is divided into two steps.
  • FIG. 8 is a drawing of enlarged cross sectional views showing the changes in shape of teeth between (B) and (C) of FIG. 7 .
  • FIG. 9 is a drawing of partial cross sectional views of when sizing is divided into two steps.
  • FIG. 10 is similar to FIG. 5 and shows a second embodiment of the present invention.
  • FIG, 11 is a drawing of cross sectional views showing the changes in shape of an intermediate material between (C) and (D) of FIG. 10 .
  • FIG. 12 is a drawing of partial cross sectional views showing the order of processing of a third embodiment of the present invention.
  • FIG. 13 is a drawing of partial cross sectional views showing the order of processing of a fourth embodiment of the present invention.
  • FIG. 14 is a pictorial view of a rack of a fifth embodiment of the present invention.
  • FIG. 15 is a view as seen from direction E in FIG. 14 .
  • FIG. 16 is a view as seen from direction F in FIG. 14 .
  • FIG. 17 is an enlarged cross sectional view of the portion G-G in FIG. 16 .
  • FIG. 18 is a drawing of partial cross sectional views from the same direction as FIG. 17 , and shows the order of processing of the manufacturing method of the fifth embodiment.
  • FIG. 19 is a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows the order of processing from a first plastic working to the initial step of a second plastic working in a sixth embodiment of the present invention.
  • FIG. 20 is similarly a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows the order of processing of a plastic working of enlarging the radius of curvature of the cross sectional shape from the base of the teeth to the tip of the teeth on both ends in the width direction of the crude rack teeth when performing the initial step of the second plastic working.
  • FIG. 21 is similarly a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows a first example of the order of processing of plastic working for adjusting the shape of the crude rack teeth and forming the rack teeth when performing the final step of the second plastic working.
  • FIG. 22 is similarly a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows a second example of the order of processing of the aforementioned plastic working.
  • FIG. 23 is a drawing of partial pictorial views of the shape from the crude rack teeth to the rack teeth as processing progresses, where (A) is the crude rack teeth after the initial step of the second plastic working, (B) is the state after plastic working is performed to enlarge the radius of curvature of the cross sectional shape of the edges on both ends in the width direction of the crude rack teeth, and (C) is the rack teeth after sizing.
  • FIG. 24 is a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows two sizing conditions of the sixth embodiment.
  • FIG. 25 is a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows the order of processing from a first plastic working to the initial step of a second plastic working in a seventh embodiment of the present invention.
  • FIG. 26 is similarly a drawing of cross sectional views as seen from the same direction as FIG. 4 , and shows the order of processing of a plastic working of enlarging the radius of curvature of the cross sectional shape of the edges on both ends in the width direction of the crude rack teeth when performing the initial step of the second plastic working.
  • FIG. 27 is similarly a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows a first example of the order of processing of a plastic working for adjusting the shape of the crude rack teeth and forming the rack teeth when performing the final step of the second plastic working.
  • FIG. 28 is a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows a second example of the order of processing during the aforementioned plastic working.
  • FIG. 29 is a drawing of partial cross sectional views as seen from the same direction as FIG. 4 , and shows two sizing conditions of the seventh embodiment.
  • FIG. 30 is a pictorial view of a rack that was made using the manufacturing method of an eighth embodiment of the present invention.
  • FIG. 31 is a drawing of partial cross sectional side views showing the order of processing of the manufacturing method of the eighth embodiment of the present invention.
  • FIG. 32 is a drawing of partial cross sectional views as seen from the H direction of FIG. 30 , and shows the order of the subsequent processing.
  • FIG. 33 is a drawing of partial pictorial views showing the shape of the rack teeth before and after sizing.
  • FIG. 34 is a drawing similar to FIG. 31 , and shows a ninth embodiment of the present invention.
  • FIG. 35 is a drawing similar to FIG. 31 , and shows a tenth embodiment of the present invention.
  • FIG. 36 is a drawing similar to FIG. 31 , and shows an eleventh embodiment of the present invention.
  • FIG. 37 is a drawing similar to FIG. 31 , and shows a twelfth embodiment of the present invention.
  • FIG. 38 is a drawing similar to FIG. 31 , and shows a thirteenth embodiment of the present invention.
  • FIG. 39 is a partial cross sectional drawing from the same direction as FIG. 31 , and shows a fourteenth embodiment of the present invention.
  • FIG. 40 is a side view showing an example of a steering apparatus for an automobile that comprises a steering gear provided with a rack which is an object of the present invention.
  • FIGS. 1 to 8 show a first embodiment of the present invention.
  • the construction of the rack 8 of this embodiment will be explained based on FIGS. 1 to 4 .
  • the radius of curvature of each surface is taken to be the radius of curvature of the cross sectional shape of each surface.
  • the rack 8 is made of a metal material such as carbon steel, stainless steel or the like, and comprises a rod unit 9 that is a solid material having a circular cross section, and rack teeth 10 that are formed by plastic working on one side surface in the radial direction of part in the axial direction (left part in FIGS. 1 to 3 ) of the rod unit 9 .
  • the rod unit 9 is made from a single metal material that is the same over the entire length from the outer surface to the center.
  • the radius of curvature R 11 see FIG.
  • the radius of curvature r 12 of the outer surface of the circular rod portion 12 which is the remaining part in the axial direction of the rod unit 9 (R 11 >r 12 ).
  • the radius of curvature r 12 of the outer surface of the circular rod portion 12 coincides with the radius of curvature of the outer surface of the original material. Therefore, the radius of curvature R 11 of the rear portion 11 is greater than the radius of curvature of the outer surface of this material.
  • the width dimension W 10 of the rack teeth 10 is greater by that amount (when compared with the case when the rack teeth are simply formed on the outer surface of the material).
  • a circular rod shaped material 13 which is a metal material such as carbon steel, stainless steel or the like, is set (placed) inside a concave groove portion 15 that is formed on the top surface of a receiving die 14 and has a circular arc shaped cross section.
  • the radius of curvature R 15 of the inner surface of this concave groove portion 15 is nearly the same as the radius of curvature of R 11 of the rear portion 11 (see FIG. 4 ) (except for the amount of springback that results after the processing force has been released) (R 15 ⁇ R 11 ).
  • the material 13 is forcefully pressed toward the concave groove portion 15 by the tip end (bottom end surface) of a pressure punch 16 which is long in the direction along the concave groove portion 15 , to perform upsetting work.
  • the shape of the pressure punch 16 is typically a flat surface.
  • the surface can be a concave curved surface having a large radius of curvature, or can be concave shaped such that both ends in the width direction protrude linearly or in a rounded manner toward the receiving die 14 (such that it embraces the top end portion of the shape after upsetting work).
  • a flat surface portion 18 that is located on the opposite side in the radial direction of the cross section from this partial cylindrical surface portion 17 , and a pair of curved portions 19 that have a relatively small radius of curvature and that connect the partial cylindrical surface portion 17 and the flat surface portion 18 .
  • this intermediate material 20 is taken from the concave groove portion 15 of the receiving die 14 , and as shown in (C) of FIG. 5 , is inserted (set) in the bottom portion of a retaining hole 22 that is formed in the die 21 .
  • This retaining hole 22 has a U-shaped cross section where the radius of curvature of the bottom portion 23 is nearly the same as the radius of curvature R 15 on the inner surface of the concave groove portion 15 of the receiving die 14 .
  • Both inside surfaces 24 are flat surfaces that are parallel with each other.
  • a pair of inclined guide surfaces 25 which is inclined in a direction such that the space between them expands going toward the top, is formed on the opening on the top end.
  • a teeth-formation punch 26 is inserted into the retaining hole 22 , and this teeth-formation punch 26 forcefully presses the intermediate material 20 inside the retaining hole 22 .
  • a wave-shaped uneven surface for forming teeth having a shape that corresponds to the rack teeth to be obtained is provided on the bottom surface of this teeth-formation punch 26 . Except for the surface portion 18 where the rack teeth will be formed, the intermediate material 20 is confined by the inner surface of the retaining hole 22 .
  • the flat surface portion 18 of this intermediate material 20 is plastically deformed to correspond to the aforementioned wave-shaped uneven surface to form a crude rack 27 having rack teeth 10 as shown in (D) of FIG. 5 and (A) of FIG. 6 .
  • the crude rack 27 in this state has insufficient shape and dimension precision when compared with the rack 8 in the completed state (see FIGS. 1 to 4 ), and the edges of the rack teeth 10 are also still sharp.
  • the crude rack 27 is removed from the retaining hole 22 , and as shown in (E) of FIG. 5 , is placed on an uneven sizing surface 30 that is formed on the top surface of a sizing die 29 .
  • This uneven sizing surface 30 has a shape that corresponds to the shape of the rack teeth 10 to be obtained that includes chamfered portion for the edges of the teeth (the uneven surface is inverted with respect to the shape of the teeth after completion).
  • a pressing die 31 forcefully presses the portion of the crude rack 27 where the rack teeth 10 are formed toward the uneven sizing surface 30 .
  • a concave pressing groove 32 having a radius of curvature that is the same as the radius of curvature R 11 (see FIG. 4 ) on the rear portion 11 of the rack 8 is formed on the bottom surface of the pressing die 31 , and with the portion that will be the rear portion 11 fitting inside the concave pressing groove 32 , the crude rack 27 is pressed forcefully toward the uneven sizing surface 30 . Therefore, as shown in (F) of FIG. 5 , with the sizing die 29 and the pressing die 31 sufficiently close together, the rack teeth 10 are formed into the completed state as shown in (B) of FIG. 6 (the shape and dimensions are precise, and the edges of each of the teeth are chamfered), and at the same time, the shape and dimensions of the rear portion 11 also become proper.
  • the sizing process can be performed in two steps as shown in FIG. 9 .
  • the sizing process shown in FIG. 9 first, as shown in (A), the crude rack 27 is tightly held between the sizing die 29 a and pressing die 31 a to form the rack teeth shape. After that, as shown in (B), the crude rack 27 is tightly held again between a receiving die 34 , in which an uneven receiving portion 33 that engages with the rack teeth 10 is formed on the top surface, and a pressing die 35 , and the shape and dimensions of the rear portion 11 is adjusted, to complete the rack 8 .
  • the collecting of excess material in both of the flat flank surface portions 28 that moves during sizing is the same as in the case of performing the process in a single motion.
  • FIG. 10 and FIG. 11 show a second embodiment of the present invention.
  • the amount of processing in the upsetting work shown in (A) to (B) of FIG. 10 is greater than that in the case of the first embodiment described above, and the width dimension of the intermediate material 20 a that is obtained in this upsetting work is larger than in the case of the first embodiment.
  • the radius of curvature of the partial cylindrical surface portion 17 a is greater than in the case of the first embodiment.
  • the intermediate material 20 a as described above is pressed into a retaining hole 22 of a die 21 while plastically deforming both end portions in the width direction.
  • This die 21 is the same as that used in the first embodiment.
  • both end portions in the width direction of the intermediate material 20 a are ironed by the continuous portion between the inside surfaces 24 and the inclined surfaces 25 of the retaining hole 22 .
  • FIG. 12 shows a third embodiment of the present invention.
  • this embodiment as shown in (A) to (B) of FIG. 12 , by performing an ironing work on a material 13 by passing it through a die 36 , the outer diameter of this material 13 is reduced except for part in the axial direction.
  • the result is taken to be a preliminary intermediate material 37 having a portion in the axial direction whose outer diameter is greater than the outer diameter of the remaining portion in the axial direction, and of this preliminary intermediate material 37 , the portion in the axial direction having the larger diameter is plastically deformed in the same manner as in the first embodiment or in the second embodiment described above to obtain a rack 8 a as shown in (C) of FIG. 12 .
  • FIG. 13 shows a fourth embodiment of the present invention.
  • a material 13 undergoes upsetting work as shown in (A) to (B) of FIG. 5 described above for example, to obtain an intermediate material 20 .
  • an ironing work of this intermediate material 20 By passing it through a die 36 as shown in (C) of FIG. 13 , the outer diameter of this intermediate material 20 is reduced except for part in the axial direction.
  • FIGS. 14 to 18 show a fifth embodiment of the present invention.
  • the rod unit 9 b comprises a combination of an outer layer member 39 and inner layer member 40 .
  • the outer layer member 39 is formed into a cylindrical tube shape from a first metal material such as carbon steel or stainless steel having superior strength and wear resistance.
  • the inner layer member 40 is formed into a circular rod shape from a lightweight second metal material such as aluminum alloy or magnesium alloy.
  • the outer layer member 39 has a length dimension equal to the rack 8 b that is to be made, and length of the inner layer member 40 is kept to a length that is equal to the length of the portion in the axial direction where the rack teeth 10 will be formed on the outer surface (a little extra length is provided such that it is a little longer than the portion where the rack teeth 10 are formed).
  • This kind of inner layer member 40 and outer layer member 39 are combined by tightly fitting the inner layer member 40 inside the part toward one end in the axial direction of the outer layer member 39 (left end in FIGS. 14 to 16 ) by heated or cooled shrink fitting or the like.
  • the material 13 a that forms the rod unit 9 b which is the combined outer layer member 39 and inner layer member 40 as described above is plastically deformed as shown in (A) to (F) of FIG. 18 for example, in the same way as in the second embodiment shown in FIG. 10 or in the first embodiment shown in FIG. 5 , to obtain the rack 8 b as mentioned above.
  • FIGS. 19 to 24 show a sixth embodiment of the present invention.
  • This embodiment differs from the second embodiment shown in FIG. 10 and described above in that, in the process of forming the rack teeth 10 , plastic working is performed to enlarge the radius of curvature of the cross sectional shape of the edges of both ends in the width direction of the crude rack teeth 43 , and in order to leave a pair of flat guide surfaces 41 that is parallel with each other on both side surfaces of the completed rack teeth 10 , a pair of flat flank surfaces 42 is formed adjacent to both flat guide surfaces 41 , the flat flank surfaces 42 being inclined in a direction such that they come closer together as they extend further away from the flat guide surfaces 41 .
  • the formation, function and advantageous effects are the same as in the second embodiment described above, so an explanation of equivalent points will be either omitted or simplified, and the following explanation will center only on the points that are different from the second embodiment.
  • a pair of flat guide surfaces 41 that is parallel with each other and a pair of flat flank surfaces 42 that is adjacent to both of these flat guide surfaces 41 are formed when processing the intermediate material 20 a in the process (C) to (D) of FIG. 19 to obtain a crude rack 27 b .
  • These flat flank surfaces 42 are located in portions on opposite sides of the crude rack teeth 43 that are formed on part in the circumferential direction of the intermediate material 20 a with both flat guide surfaces 41 as borders, and are inclined in a direction such that the space between them becomes more narrow going away from both flat guide surfaces 41 .
  • a pair of second flat formation surfaces 45 that is inclined in a direction such that the space between them becomes more narrow going away from a pair of flat formation surfaces 44 that is parallel with each other is provided in areas that are adjacent to the side of the bottom portion 23 a of the pair of flat formation surfaces 44 in a portion of the inside surfaces of a retaining hole 22 a , which is a concave formation groove that is formed in a die 21 a .
  • the flat flank surfaces 42 are formed in portions that correspond to the second flat formation surfaces 45 to obtain the crude rack 27 b as shown in (A) of FIG. 23 .
  • crude rack teeth 43 are formed by a teeth-formation punch 26 a having a shape that corresponds to a pressure angle that is less than the pressure angle of the rack teeth to be obtained, and the crude rack 27 b is obtained.
  • plastic working is performed to increase the radius of curvature of the cross sectional shape from the base of the teeth to the tip of the teeth on both ends in the width direction of the crude rack teeth 43 .
  • the radius of curvature from the base of the teeth to the tip of the teeth on both ends in the width direction of the crude rack teeth 43 is increased, and curved portions 48 as shown in (B) of FIG. 23 are formed from the base of the teeth to the tip of the teeth on the edges on both end in the width direction of the crude rack teeth 43 .
  • These curved portions 48 are formed for preventing the edges on both ends in the width direction of the completed rack teeth 10 from interfering with other members, and for preventing concentrated stress at the edges.
  • this embodiment reduces the load on the metal dies that are used in the process of plastic working of the rack teeth 10 by forming curved portions 48 as shown in (B) of FIG. 23 , as well as this embodiment prevents the occurrence of burrs, thus making it possible to obtain good shape precision and dimension precision of the obtained rack teeth 10 .
  • the metal material that moves due to the plastic working of the curved portions 48 described above stops at the flat flank portions 42 , which prevents the excess material from protruding out in the radial direction further than a virtual cylindrical surface that extends from the partial cylindrical surface 17 a.
  • the radius of curvature of the curved portions 48 that are formed on the edges of both ends in the width direction of the crude rack teeth 43 is made to be larger than the radius of curvature of the curved portions that remain on both ends in the width direction of the completed rack teeth 10 .
  • the reason for this is to maintain the radius of curvature of the curved portions that remain on both ends in the width direction of the completed rack teeth 10 because in the process of finishing the crude rack teeth 43 into the rack teeth 10 as shown in (A) to (B) of FIG. 21 or FIG. 22 , and (B) to (C) of FIG. 23 and explained below, there is a tendency for the radius of curvature of the curved portions 48 from the base of the teeth to the tip of the teeth on the edges on both ends in the width direction to become small.
  • the second intermediate material 49 that is formed with curved portions 48 as described above is pressed inside the retaining hole 22 b of a die 21 b by a teeth-formation punch 26 in the same way as in the rust embodiment, to form rack teeth 10 .
  • the inside dimension of the retaining hole 22 b can be the same as the width dimension of the second intermediate material 49 , or as shown in FIG. 22 , can be a little smaller than the width dimension.
  • the flat guide surfaces 41 that are located on both ends in the width direction of the second intermediate material are ironed in the process of forming the rack teeth 10 .
  • the rack teeth 10 are formed on the surface of one side in the circumferential direction, and a rack 8 c is obtained in which the characteristics of the flat guide surfaces 41 have been made proper.
  • the rack 8 c that has been obtained in this way can be used as is, however, when necessary sizing is performed in order to improve the precision of the rack teeth 10 .
  • This sizing is essentially performed in the same way as in the first embodiment described above. However, when it is necessary to maintain the precision of the flat guide surfaces 41 , sizing is performed while restrain these flat guide surfaces 41 by restraining surfaces 50 as shown in (A) of FIG. 24 . On the other hand, when it is not necessary to maintain the precision of these flat guide surfaces 41 , it is only necessary to press the rack 8 a into the receiving die 34 as shown in (B) of FIG. 24 .
  • the flat guide surfaces engage with the linear portion of a guide sleeve and are provided in order to prevent the rack 8 a from displacement in the rotational direction.
  • FIGS. 25 to 29 show a seventh embodiment of the present invention.
  • This embodiment shows the case in which the construction of the fifth embodiment shown in FIGS. 14 to 18 and described above is made by the manufacturing method of the sixth embodiment described above.
  • FIG. 25 that shows this embodiment corresponds with FIG. 19 that shows the sixth embodiment, and similarly FIGS. 26 to 28 correspond with FIGS. 20 to 22 , and FIG. 29 corresponds with FIG. 24 .
  • FIGS. 30 to 33 show an eighth embodiment of the present invention. First, the construction of the rack 8 e that is made by the manufacturing method of this embodiment will be explained using FIG. 30 .
  • This rack 8 e comprises: a solid rod unit 9 e having a circular cross section and is made of a metal material such as carbon steel or stainless steel; and rack teeth 10 that are formed by plastic working of the surface on one side in the radial direction of part in the axial direction (left portion in FIG. 30 ) of the rod unit 9 e .
  • the rod unit 9 e is made from a single metal material that is the same over the entire length and from the outer surface to the center.
  • the radius of curvature R 11 see (B) of FIG.
  • a pair of flat guide surfaces 41 a that is parallel with each other is provided at two locations on the outer surface of the rack 8 e that are separated in the circumferential direction, with each being continuous in the axial direction of the rack 8 e .
  • These flat guide surfaces 41 a are located along a direction that is orthogonal to a virtual plane that comes in contact with tips of the rack teeth 10 that are formed on the surface of one side of the rack 8 e .
  • the flat guide surfaces 41 a are continuous in the axial direction from the portion on the outer surface of the rod unit 9 e that corresponds to the portion where the rack teeth 10 are formed to the tip end (left end in FIG. 30 ).
  • these flat guide surfaces 41 a are formed, in a state that the rack 8 e is installed in a steering apparatus, to engage (slidingly contact) with the sliding portion on the inner surface of a guide sleeve for supporting the rack 8 e such that the rack 8 e is capable of moving in the axial direction inside a housing, and to prevent the rack 8 e from rotating around its own center axis.
  • the outer diameter of the remaining portion in this axial direction with respect to this reduced diameter portion or in other words, the outer diameter of the portion that corresponds to the portion where the rack teeth 10 are to be formed and the outer diameter of the portion further toward the tip end side (left end side in FIG. 31 ) than this portion is greater than the outer diameter of the portion in the axial direction with reduced diameter (portion further toward the base end side than the portion that corresponds to the portion where the rack teeth 10 are to be formed), where this resulting material is taken to be a first intermediate material 60 .
  • the reason for making the diameter of the base end side portion less than that of the portion that corresponds to the portion where the rack teeth 10 are to be formed is to make it possible for the completed rack 8 e to be more lightweight.
  • the diameter of the reduced diameter portion in the axial direction of the intermediate material 60 is reduced (performed over two steps), to obtain a second intermediate material 61 .
  • the reason for making the outer diameter of the portion that is nearer the tip end side than the portion corresponding to where the rack teeth 10 will be formed greater than the outer diameter of the portion that corresponds to the portion where the rack teeth 10 will be formed in this way is in order to make the surface around the rear surface of the flat surface portion, or in other words, the rear portion 11 , continuous with the surface around the portion on the tip end side, with the radius of curvature R 11 of the rear portion 11 being increased due to the formation of the flat surface portion in the portion where the rack teeth 10 are to be formed (in order to leave metal material that is necessary for making the surfaces continuous).
  • the flat guide surface 41 a reaching up to the edge on the tip end of the rod unit 9 e (see FIG. 30 ).
  • the second intermediate material 61 shown in (C) of FIG. 31 has been formed as described above, then as shown in (A) of FIG. 32 , the second intermediate material 61 (the portion that corresponds with the portion where the rack teeth 10 will be formed and the portion that is nearer the tip end side than that portion) is set (placed) inside a concave groove portion 15 having an arc shaped cross section that is provided on the top surface of a receiving die 14 .
  • the radius of curvature R 15 of the inner surface of the concave groove portion 15 is nearly equal to radius of curvature R 11 (see (B) of FIG.
  • the tip end surface (bottom end surface) of a long pressure punch 16 that runs along the length of this concave groove portion 15 forcefully presses the second intermediate member 61 (the portion that corresponds to the portion where the rack teeth 10 will be formed) toward the concave groove portion 15 , to perform a upsetting work (first plastic working).
  • the shape of the tip end surface of the pressure punch 16 is generally a flat surface. However, it could also be a concave curved surface having a large radius of curvature with respect to the width direction of the concave groove portion 15 (left and right direction in FIG. 32 ), or it could be a concave shape in which both end portions in the width direction protrude out linearly or in a curved manner toward the receiving die 14 (a shape that embraces the top end of the shape after upsetting work). In any case, in the upsetting work shown in (B) of FIG.
  • This third intermediate material 62 comprises: a partial cylindrical surface portion 17 b on the outer surface of the portion where the rack teeth 10 will be formed and that will become the rear portion 11 ; a flat surface portion 18 that is located on the opposite side in the radial direction of the cross section from the partial cylindrical surface portion 17 b ; and a pair of curved surface portions 19 that connects both surfaces 17 b and 18 and that has a relatively small radius of curvature.
  • partial cylindrical surface portion 17 b is continuous with the outer surface of the portion nearer the tip end side than the portion that corresponds to the portion where the rack teeth 10 will be formed (remaining portion on the tip end portion of the second intermediate material 61 whose diameter was not reduced during the second ironing work).
  • the third intermediate material 62 is removed from the concave groove portion 15 of the receiving die 14 , and as shown in (C) of FIG. 32 , is inserted (set) into an opening of a concave formation groove (retaining hole) 22 c that is located on a formation die 21 c .
  • This concave formation groove 22 c has a U-shaped cross section, and the radius of curvature of the bottom portion 23 b is nearly equal to the radius of curvature R 15 of the inner surface of the concave groove portion 15 of the receiving die 14 .
  • the inner width of the concave formation groove 22 is a little less than the outer width of the third intermediate material 62 .
  • a pair of flat formation surfaces 44 a that are parallel with each other is provided in the middle in the depth direction (vertical direction in (C) and (D) of FIG. 32 ) of both inner surfaces of the concave formation groove 22 .
  • a pair of inclined guide surfaces 25 which are inclined in a direction such that the space between them increases going in the upward direction, is provided in the opening in the top end.
  • the third intermediate material 62 is set in the opening of the concave formation groove 22 c so that it spans between the inclined guide surfaces 25 .
  • an uneven wave-shaped formation surface that corresponds to the rack teeth 10 to be obtained is provided on the bottom surface of the teeth-formation punch 26 for pressing the third intermediate material 62 inside the concave formation groove 22 c . Therefore, after the teeth-formation punch 26 has pressed the third intermediate material 62 to the bottom portion 23 b of the concave formation groove 22 c , the teeth-formation punch 26 forcefully presses the third intermediate material 62 further so that the uneven wave shape is transferred to part of the third intermediate material 62 to form crude rack teeth 43 in that portion. As a result, the third intermediate material 62 that is shown in (C) of FIG. 32 becomes the crude rack 27 c that is shown in (D). However, when compared with the completed rack 8 e , the shape precision and dimension precision of the crude rack 27 c in this state is insufficient, and the edges of the ends of the crude rack teeth 43 are still sharp.
  • the metal material that is extruded (from the portion that will be the bottom of the teeth) while forming the crude rack teeth 43 is forcefully pressed against the flat formation surfaces 44 a of the concave formation groove 22 c .
  • the portion of the crude rack 27 c that is further toward the tip end side than the crude rack teeth 43 (left end portion in (C) of FIG. 31 ) is also pressed inside the concave formation groove 22 c by the portion of the bottom surface of the teeth-formation punch 26 that is separated from the uneven wave-shaped portion.
  • the flat guide surfaces 41 a which are parallel with each other, are formed so that they reach to the edge on the tip end in the axial direction of this crude rack 27 c.
  • These flat guide surfaces 41 a are located such that they are orthogonal to a virtual plane that comes in contact with the tip of the teeth of the crude rack teeth 43 .
  • the teeth-formation punch 26 is raised and the crude rack 27 c is removed from the concave formation groove 22 c , then as shown in (E) of FIG. 32 , it is placed on an uneven sizing surface 30 that is formed on the top surface of a sizing die 29 b .
  • This uneven sizing surface 30 has a shape that corresponds to the shape of the rack teeth 43 to be obtained, including a chamfered portion for the edges on the end of the teeth (the uneven shape is inverted with respect to the completed shape).
  • a pair of restraining surfaces 50 which are flat surfaces that are parallel with each other, is provided on both sides of the uneven sizing surface 30 and they restrain the flat guide surfaces 41 a .
  • a pressing die 31 b forcefully presses the portion where the crude rack teeth 43 are formed on the crude rack 27 c toward the uneven sizing surface 30 .
  • a concave pressing groove 32 is formed on the bottom surface of the pressing die 31 b so that it has a radius of curvature that is equal to the radius of curvature R 11 of the rear portion 11 of the rack 8 e to be made, and with the portion that will become the rear portion 11 fitted inside the concave pressing groove 32 , the crude rack 27 c is forcefully pressed toward the uneven sizing surface 30 . Therefore, with the sizing die 29 b and the pressing die 31 b sufficiently close as shown in (F) of FIG. 32 , the rack teeth 10 become the completed rack teeth 10 shown in (B) of FIG. 33 from the crude rack teeth 43 having sharp edges shown in (A) of FIG.
  • the shape and dimensions become proper, and the edges of each of the teeth become chamfered), and at the same time the shape and dimensions of the rear portion 11 also become proper.
  • the flat guide surfaces 41 a are pressed against the restraining surfaces 50 , improving the surface precision.
  • the rack 8 e that is obtained in this way, it is possible to secure the width dimension, strength and rigidity of the rack teeth, and lighten the weight of the rack 8 e without increasing more than necessary the outer diameter of the portion where the rack teeth 10 are not formed (outer diameter of the base end side of the rack teeth 10 ).
  • plastic working of the flat guide surfaces 41 a is performed at the same time that plastic working of the rack teeth 10 is performed, so the rack 8 e having the desired shape with flat surfaces 41 a can be made at low cost.
  • a first and second ironing works are performed for bringing the outer diameter of the material 13 (cross sectional shape) to a desired value. Therefore, in addition to preventing excess material from protruding outward in the radial direction and becoming burrs, and improving yield by reducing material costs, it is possible to control the processing load required for forming the rack teeth 10 and eliminate the need for processing afterward to remove the excess material.
  • this embodiment makes it so that this kind of excess material does not occur (the excess material is moved), but due to the shape that is required after the rack 8 e has been completed, the desired shape can be regulated, taking into consideration the metal material that is extruded by the plastic working.
  • the ironing work which is a kind of plastic working, for regulating the shape (cross sectional shape) of the material 13 in this way can segue into the other plastic working for forming the rack teeth 10 or the like. Therefore, the production process for the overall rack 8 e can be performed with good efficiency, so by performing the ironing work described above, it is possible to suppress an increase in production cost of the rack 8 e somewhat. In addition, there is no need for processing equipment for cutting, grinding, gun drilling or the like, so from the aspect of keeping equipment related investment to a minimum as well, the rack 8 e can be manufactured at low cost.
  • FIG. 34 shows a ninth embodiment of the present invention.
  • a second ironing work is performed on the first intermediate material 60 on which a first ironing work was performed by passing the first intermediate material 60 through a second die 36 c as shown in (C) to (D) of FIG. 34 .
  • the outer diameter of the portion of the first intermediate material 60 where the rack teeth 10 (see FIG. 1 ) are to be formed and the portion further toward the tip end side than the portion corresponding to where the rack teeth 10 are to be formed is reduced.
  • construction see (C) of FIG.
  • the outer surface of the tip end portion by compressing the outer surface of the tip end portion (pushing up the metal material of the portion on the tip end that corresponds to the rear portion), the metal material of the portion of the tip end corresponding to where the flat guide surfaces 41 a are to be formed is ensured, and therefore these flat guide surfaces 41 a can be formed such that they reach the edge of the tip end of the rack 8 e , being continuous along the axial direction of the rack 8 e .
  • the outer surface can be made continuous (unevenness in the outer surface can be eliminated) without having to compress the outer surface of the tip end portion in this way.
  • FIG. 35 shows a tenth embodiment of the present invention.
  • an ironing work is performed on the material 13 as shown in (A) to (B) of FIG. 35 , and the outer diameter of the portion further toward the base end side than the portion corresponding to where the rack teeth 10 (see FIG. 30 ) will be formed is reduced to obtain a first intermediate material 60 a .
  • a rack 8 e is formed, for example as shown in FIG. 30 .
  • a second ironing work as in the case of the eighth and ninth embodiments described above is not performed.
  • the ironing work described above is performed before performing the upsetting work (plastic working), however, it is also possible to perform the ironing work after finishing the upsetting work (plastic working) shown in (A) to (B) of FIG. 32 . Deciding which process to perform is determined by taking into consideration whether the plastic working and ironing works can be performed well together. Whether or not to form the flat guide surfaces 41 a (see FIG. 30 ), or whether or not to form the flat guide surfaces 41 a so that they reach the edge on the tip end of the rack 8 e (see FIG. 30 ) can be freely decided. A diameter expansion process such as explained in the ninth embodiment above can also be used as needed.
  • FIG. 36 shows an eleventh embodiment of the present invention.
  • an ironing work is performed on the material 13 as shown in (A) to (B) of FIG. 36 , and the outer diameter, except that of the portion further toward the tip end side than the portion corresponding to where the rack teeth 10 (see FIG. 30 ) will be formed, is reduced to obtain a first intermediate material 60 b .
  • a rack 8 e is formed, for example as shown in FIG. 30 .
  • an ironing work is not performed in order to the outer diameter of the portion nearer the base end side than the portion corresponding to where the rack teeth 10 are to be formed smaller than that of the portion where the rack teeth 10 will formed as was done in the eighth to tenth embodiments described above.
  • an ironing work such as described in the tenth embodiment (see FIG. 35 ) after performing the ironing work shown in (A) to (B) of FIG. 36 described above, it is possible to reduce the outer diameter of the portion nearer the base end side than the portion corresponding to where the rack teeth 10 will be formed. By reducing the outer diameter of the base end side in this way, it is possible to lighten the weight.
  • FIG. 37 shows a twelfth embodiment of the present invention.
  • an ironing work is performed on the material 13 as shown in (A) to (B) of FIG. 37 , and the outer diameter of the portion corresponding to where the rack teeth 10 (see FIG. 30 ) will be formed, and that of the portion further toward the tip end side than that portion are reduced to obtain a first intermediate material 60 c .
  • a rack 8 e is formed, for example as shown in FIG. 30 .
  • the outer diameter of the portion further toward the base end side than the rack teeth 10 is not reduced unlike in the rack 8 e shown in FIG. 30 , and the outer diameter of this portion is left the same as the outer diameter of the material 13 , making it possible to secure the rigidity of this portion.
  • FIG. 38 shows a thirteenth embodiment of the present invention.
  • an ironing work is performed on a preliminary material 63 as shown in (A) to (C) of FIG. 38 to reduce the outer diameter over the entire axial direction of the preliminary material 63 to obtain the material 13 .
  • an ironing work as shown in FIGS. 31 , 34 to 37 is performed as needed on this material 13 , and by performing plastic working as shown in FIG. 32 and described above, a rack 8 e as shown in FIG. 30 is obtained.
  • FIG. 39 shows a fourteenth embodiment of the present invention.
  • a diameter expansion punch 64 having a diameter that is smaller than the material 13 is pressed in the axial direction against the end surface in the axial direction of the circular rod shaped material 13 , and a concave hole 66 is formed in the end in the axial direction of the material 13 by plastic working.
  • a concave hole 66 By forming a concave hole 66 in this way in at least part in the axial direction of the material 13 , the outer diameter of the portion where this concave hole 66 is formed is increased (diameter expansion is performed).
  • the tip end portion in the axial direction of the material 13 (left end in FIG. 39 ) inserted into a diameter expansion die 65 , by bringing the punch 64 in contact with the tip end surface of the material 13 and plastically deforming the tip end of the material 13 to form the concave hole 66 , the outer diameter of part in the axial direction of the material 13 is increased in the portion nearer to the tip end side than the portion where the rack teeth 10 (see FIG. 30 ) will be formed.
  • the reason for increasing the outer diameter of this portion in this way is similar to the reason for increasing the outer diameter of that portion shown in FIG. 31 or FIG.
  • the concave hole 66 that is formed on the tip end surface by the punch 64 can be used as a bottom tap hole when forming a female screw. In addition, it is also possible to tightly fit a metal material inside the concave hole 66 to close off this concave hole 66 .
  • the diameter expansion process described above can be performed after the second intermediate material 61 a shown in (D) of FIG. 34 is formed by reducing the diameter of the outer diameter of the portion of part in the axial direction of the material 13 (does not mean the same portion as the ‘part’ where diameter expansion is performed) nearer to the base end portion than the portion that corresponds to where the rack teeth 10 will be formed as done in the ninth embodiment shown in FIG. 34 and described above, or can be performed while (performed at the same time as) performing the second ironing work shown in (C) of FIG. 34 .
  • the diameter expansion process described above can be performed after the first intermediate material 60 a shown in (B) of FIG.
  • 35 is formed by reducing the diameter of the outer diameter of the portion of part in the axial direction of the material 13 (does not mean the same portion as the ‘part’ where diameter expansion is performed) nearer to the base end portion than the portion that corresponds to where the rack teeth 10 will be formed as done in the tenth embodiment shown in FIG. 35 and described above, or can be performed while (performed at the same time as) performing the ironing work shown in (B) of FIG. 35 .
  • the diameter expansion process described above can be performed after the first intermediate material 60 c shown in (B) of FIG. 37 is formed by reducing the diameter of the outer diameter of the portion of part in the axial direction of the material 13 (does not mean the same portion as the ‘part’ where diameter expansion is performed) that corresponds to where the rack teeth 10 will be formed as done in the twelfth embodiment shown in FIG. 37 and described above.
  • the diameter expansion process described above can be performed after the material 13 as shown in (C) of FIG. 38 is formed by reducing the outer diameter along the entire axial direction of the preliminary material 63 as done in the thirteenth embodiment shown in FIG. 38 . After the diameter expansion process has been performed as described above, plastic working as shown in FIG. 32 and described above is performed to obtain a rack 8 e as shown in FIG. 30 .
  • the rack of the present invention can be applied as a rack for a steering gear unit 5 as shown in FIG. 40 and described above, and makes it possible to reduce the cost and lighten the weight of the steering gear unit 5 .
  • the present invention is not limited to use in this kind of steering gear unit 5 , and can be applied as the rack installed in various kinds of machinery and the like, contributing to the cost reduction and weight reduction of the machinery.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Forging (AREA)
  • Gears, Cams (AREA)
US12/447,785 2006-11-02 2007-10-30 Rack and manufacturing method thereof Abandoned US20100162843A1 (en)

Applications Claiming Priority (7)

Application Number Priority Date Filing Date Title
JP2006299437 2006-11-02
JP2006-299437 2006-11-02
JP2007132561A JP5352965B2 (ja) 2006-11-02 2007-05-18 ラックの製造方法
JP2007-132561 2007-05-18
JP2007-166047 2007-06-25
JP2007166047A JP2009000734A (ja) 2007-06-25 2007-06-25 ラック及びその製造方法
PCT/JP2007/071140 WO2008053896A1 (en) 2006-11-02 2007-10-30 Rack and production method thereof

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US13/415,120 Abandoned US20120186085A1 (en) 2006-11-02 2012-03-08 Rack and manufacturing method thereof

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EP (1) EP2082818A4 (zh)
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DE102012107438A1 (de) * 2012-08-14 2014-03-27 Dematic Accounting Services Gmbh Verfahren zur Herstellung einer Zahnstange
US20150000135A1 (en) * 2013-07-01 2015-01-01 Jtekt Corporation Blank and method of manufacturing rack shaft using the same
US20160236705A1 (en) * 2015-02-17 2016-08-18 Hyundai Motor Company Rack bar unit of vehicle steering device
US20160271726A1 (en) * 2012-12-27 2016-09-22 Neturen Co., Ltd. Rack manufacturing apparatus and rack manufacturing method
US20180043925A1 (en) * 2016-08-09 2018-02-15 Steering Solutions Ip Holding Corporation Steering rack and method of manufacturing the same
US9914166B2 (en) 2013-02-26 2018-03-13 Nsk Ltd. Rack, method for manufacturing rack, and device for manufacturing rack
US20190247951A1 (en) * 2016-07-06 2019-08-15 Thyssenkrupp Presta Ag Rack and method for producing a rack for a steering gear of a motor vehicle
US10392046B2 (en) 2014-01-22 2019-08-27 Nsk Ltd. Steering rack and method for manufacturing the same
US10562138B2 (en) * 2015-11-04 2020-02-18 Neturen Co., Ltd. Method for manufacturing rack bar
US10612642B2 (en) 2013-06-03 2020-04-07 Neturen Co., Ltd. Method for manufacturing rack and hollow rack bar
US20200172151A1 (en) * 2018-11-30 2020-06-04 Steering Solutions Ip Holding Corporation Steering system rack with flattened portion
US10926788B2 (en) * 2016-07-06 2021-02-23 Thyssenkrupp Presta Ag Method for producing a toothed rack for a motor vehicle
US11072360B2 (en) * 2016-07-06 2021-07-27 Thyssenkrupp Presta Ag Gear rack and method for producing a gear rack for a steering gear of a motor vehicle
US11077875B2 (en) 2016-07-06 2021-08-03 Thyssenkrupp Presta Ag Rack and a method for producing a rack for a steering gear of a motor vehicle
US11298765B2 (en) 2016-07-06 2022-04-12 Thyssenkrupp Presta Ag Toothed rack and method for producing a toothed rack for a steering gear of a motor vehicle
US11628524B2 (en) * 2020-11-17 2023-04-18 Fujifilm Business Innovation Corp. Manufacturing method of staple-less binding unit

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JP5773386B2 (ja) * 2011-10-05 2015-09-02 トヨタ車体株式会社 ラック歯を一体形成した部品
CN102632097A (zh) * 2012-05-17 2012-08-15 南京康尼机电股份有限公司 一种管状工件的成型装置及其成型方法
JP6088783B2 (ja) * 2012-10-15 2017-03-01 高周波熱錬株式会社 ラック付き管部材製造方法
JP6175940B2 (ja) * 2013-07-01 2017-08-09 株式会社ジェイテクト ラックシャフトの製造方法
CN103567728B (zh) * 2013-10-18 2016-05-11 盐城金刚星齿轮厂 一种零件内齿精密成形方法
CN103586649A (zh) * 2013-11-21 2014-02-19 太仓宝达齿条有限公司 一种非标齿条加工工艺
US10562559B2 (en) * 2014-08-25 2020-02-18 Hitachi Automotive Systems, Ltd. Rack bar and method for manufacturing rack bar
CN106141052B (zh) * 2016-08-10 2019-04-23 宁波甬微集团有限公司 一种空调压缩机曲轴的制造方法及其空调压缩机曲轴
CN111065845B (zh) * 2017-09-07 2024-02-23 日本精工株式会社 齿条及其制造方法、以及操舵装置、车辆以及齿条的预成形用金属模具
JP7037906B2 (ja) * 2017-10-10 2022-03-17 高周波熱錬株式会社 ラックバーの製造方法及びラックバー
PL233273B1 (pl) * 2017-11-30 2019-09-30 Lubelska Polt Sposób kucia kul z główki szyny kolejowej
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Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103600014A (zh) * 2011-12-31 2014-02-26 无锡透平叶片有限公司 用于轴对称结构棒料局部拔长的胎模拔长装置
DE102012107438A1 (de) * 2012-08-14 2014-03-27 Dematic Accounting Services Gmbh Verfahren zur Herstellung einer Zahnstange
US20160271726A1 (en) * 2012-12-27 2016-09-22 Neturen Co., Ltd. Rack manufacturing apparatus and rack manufacturing method
US9914166B2 (en) 2013-02-26 2018-03-13 Nsk Ltd. Rack, method for manufacturing rack, and device for manufacturing rack
US10612642B2 (en) 2013-06-03 2020-04-07 Neturen Co., Ltd. Method for manufacturing rack and hollow rack bar
US20150000135A1 (en) * 2013-07-01 2015-01-01 Jtekt Corporation Blank and method of manufacturing rack shaft using the same
US9492897B2 (en) * 2013-07-01 2016-11-15 Jtekt Corporation Blank and method of manufacturing rack shaft using the same
US10392046B2 (en) 2014-01-22 2019-08-27 Nsk Ltd. Steering rack and method for manufacturing the same
US11021184B2 (en) 2014-01-22 2021-06-01 Nsk Ltd. Steering rack and method for manufacturing the same
US20160236705A1 (en) * 2015-02-17 2016-08-18 Hyundai Motor Company Rack bar unit of vehicle steering device
US9744985B2 (en) * 2015-02-17 2017-08-29 Hyundai Motor Company Rack bar unit of vehicle steering device
US10562138B2 (en) * 2015-11-04 2020-02-18 Neturen Co., Ltd. Method for manufacturing rack bar
US10919107B2 (en) * 2016-07-06 2021-02-16 Thyssenkrupp Presta Ag Rack and method for producing a rack for a steering gear of a motor vehicle
US10926788B2 (en) * 2016-07-06 2021-02-23 Thyssenkrupp Presta Ag Method for producing a toothed rack for a motor vehicle
US20190247951A1 (en) * 2016-07-06 2019-08-15 Thyssenkrupp Presta Ag Rack and method for producing a rack for a steering gear of a motor vehicle
US11072360B2 (en) * 2016-07-06 2021-07-27 Thyssenkrupp Presta Ag Gear rack and method for producing a gear rack for a steering gear of a motor vehicle
US11077875B2 (en) 2016-07-06 2021-08-03 Thyssenkrupp Presta Ag Rack and a method for producing a rack for a steering gear of a motor vehicle
US11298765B2 (en) 2016-07-06 2022-04-12 Thyssenkrupp Presta Ag Toothed rack and method for producing a toothed rack for a steering gear of a motor vehicle
US20180043925A1 (en) * 2016-08-09 2018-02-15 Steering Solutions Ip Holding Corporation Steering rack and method of manufacturing the same
US20200172151A1 (en) * 2018-11-30 2020-06-04 Steering Solutions Ip Holding Corporation Steering system rack with flattened portion
US11628524B2 (en) * 2020-11-17 2023-04-18 Fujifilm Business Innovation Corp. Manufacturing method of staple-less binding unit

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EP2082818A1 (en) 2009-07-29
WO2008053896A1 (en) 2008-05-08
EP2082818A4 (en) 2014-09-10
CN101547759B (zh) 2013-03-20
CN101547759A (zh) 2009-09-30
US20120186085A1 (en) 2012-07-26

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